Under The Guidance of : Mr. Mr. Mr. Mr. Mr. Mr.

. Mr. Atul Bhatnagar (HOD) Tarun Gupta Pawan Kumar Jalaj Mathur Maninder Singh Sundeep Jain

Attended By :- Atul Kaushik

Electricity ,now a days are generated form different type of power sources and that can be classified in to Permanent power systems and Alternative power system that can generate AC voltage of any frequency . Permanent Power systems are those that supplies AC line to our Home ,industry etc. and its source is natural resources but output results in step down AC Voltage. Alternative Power System are those that generates AC voltage from any DC source with the help of electrical device know as inverter/HUPS or power back-up solutions.

 Hydro Electricity

Thermal Energy
Wind Power Solar Power Biomass Energy Nuclear Energy

 Inverter Uninterrupted Power Supply(UPS)

Off-Line UPS On-Line UPS Static UPS Line Interactive UPS

Solar Inverters

Inverter :-

It is an device that will convert DC source voltage to AC voltage and the generated AC can be of any magnitude and frequency. Need Of Inverters:The inverter is one of the most important component of Alternative Energy System . Most of our household appliances are of the AC-type and have a voltage of 220/120V for example. The converter convert the Direct Current to Alternating Current and set the output voltage in this case to 220/120V AC, which has the same specifications as the utility grid.

Uninterrupted Power Supply:-

It is an electrical apparatus that provides emergency power to a load when the input power source, typically mains power, fails. A UPS differs from an auxiliary or emergency power system or standby generator in that it will provide near-instantaneous protection from input power interruptions, by supplying energy stored in batteries . The on-battery runtime of most uninterruptible power sources is relatively short (only a few minutes) but sufficient to start a standby power source or properly shut down the protected equipment.
Need:-A UPS is typically used to protect computers, data

centers, telecommunication equipment or other electrical equipment where an unexpected power disruption could cause injuries, fatalities, serious business disruption or data loss.

 UPS :- It is used with application where user product is

depend upon the alternative supply system and its interruption can harm system failure or data lose. The Cutoff voltage for mains is 180V(Lower) and 265 V (Upper) AC. It is not suitable where we have to drive heavy load that required high initial current. Inverters :- The inverter have response time near about 50ms so these are basically used to power up our home appliances like FAN, TV, Lights etc. The cutoff voltage for mains is 100V(Lower) and 280 V (Upper) AC. It is not suitable where we have to drive heavy load that required high initial current.

Mains Supply

Power Stage

Power X-mer

Relay/SCR

Load

Battery Bank

DSP CONTROL

A.C. Line:- It is an AC input coming to our homes from

permanent energy system used to drive load and also used to do charging.
Relay/SCR:-It is used to transfer Running load to backup

supply or on AC main supply. SCR are used in static UPS and Relay are used lower VA off line UPS/Inverters.
Battery Charger: It is an AC to DC converter and its output

will be used for charging battery Simultaneously system will maintains the battery charging current . If the AC power input line lost the charger will remain idle until power is restored.
Battery:- It is used to drive load when AC line loses power.

Inverter:- The inverter will change DC power from battery to

AC power to drive load in the absence of AC line, while doing charging during its presence.
Sensors:- This part is used to provide feedback from different

sources to DSP so that it can able to take decision like overload, mains cut ,High and Low mains ,Battery charging ,Temperature etc
Load:-

The load may be any appliance working on AC 220 V , 50Hz.

Off-Line UPS:- The offline UPS offers only the most basic features,

providing surge protection and battery backup. The protected equipment is normally connected directly to incoming utility power. When the incoming voltage falls below a predetermined level the UPS turns on its internal DC-AC inverter circuitry, which is powered from an internal storage battery. The UPS then mechanically switches the connected equipment on to its DC-AC inverter output. The switchover time can be as long as 20 milliseconds depending on the amount of time it takes the standby UPS to detect the lost utility voltage.
Static UPS:-

As we know from last discussion ,UPS is a electronic device that have fast changeover time and protect to running appliances form sudden power failure. So to provide fast change over we will use Solid state relay instead of electromechanical relay at higher KVA. Rest of the principle for Static UPS remains same as that of Off-Line UPS.

The online UPS is ideal for environments where electrical isolation is necessary or for equipment that is very sensitive to power fluctuations. The basic technology of the online UPS is the same as in a Off-Line UPS. The Online UPS is having a much greater current AC-to-DC batterycharger/rectifier and inverter designed to run continuously with improved cooling systems. It is called a double-conversion UPS due to the rectifier directly driving the inverter, even when powered from normal AC current. In an online UPS, the batteries are always connected to the inverter, so that no power transfer switches(RELAY/SCR) are necessary. When power loss occurs, the rectifier simply drops out of the circuit and the batteries keep the power steady and unchanged. When power is restored, the rectifier resumes carrying most of the load and begins charging the batteries, though the charging current may be limited to prevent the high-power rectifier from overheating the batteries and boiling off the electrolyte.

A.C. Line Load

A.C. To D.C. Converter

Battery

Inverter

A.C. Line:- The AC line here representing the AC input that

are coming to our home from permanent energy system .The input will be 230 V AC ,50Hz. This will be used to drive our appliances and also used to charge battery. AC-DC Converter:-This card is used to provide DC voltage to battery so that it will remain charged .The input to this card is from A.C. Line. Battery:- It is used to drive load when AC line loses power.
Inverter:- The inverter will change the DC voltage stored in

the battery to AC voltage .

H-Bridge :- A H-bridge topology is used to generate sine wave pulse in the inverters. In the H-Bridge circuits we have 4 switches working 2 at a time to generate +VE output and another 2 at next time to generate VE output. Push-Pull Topology:-A pushpull converter is a type of DC-toDC converter used to generate square waveform in the inverters. It is a switching converter that uses a transformer to change the voltage of a DC power supply . In the push-pull circuits we use two switches working one at a time to generate +VE waveform and another at next time to generate VE waveform.

Square Waveform Due to push-pull topology there is large THD in the product . The appliances working on these ,produces noise and large amount of heat.
Low Cost Product. In the square wave inverters ,the RMS value is equals to the peak voltage hence power output is totally depend upon the battery voltage . Even Square wave inverters have higher efficiency but the appliances efficiency start decreasing .

SINE Waveform Due to H-Bridge topology there is very less THD as compare to sq. wave As wave generated are same as Permanent power systems ,and our home appliances are made according to that so there is no heat lose and noise generation. Costlier then Square wave. As Sine wave is PWM based system and its RMS voltage is not directly rated to the Battery voltage and output AC voltage can be change by varying Pulse Width . The Sine wave inverters have little lower efficiency then square wave but the appliances efficiency is better then working on square wave..

Lower KVA Inverters/HUPS:- Up to 3.5KVA Static UPS are considered under lower VA product range . In the lower VA systems we usually have only one single PCB that contains Power supply section ,Control Card ,Driver section and MOSFETS , Relays . We use maximum of 48V battery in this range. Higher KVA Inverter/HUPS and ONLINE UPS:All the product above 3.5KVA are considered under higher KVA range. In the Higher KVA range we make three different products like ONLINE UPS , Static UPS , Inverts . In the higher KV systems we have different cards to like (1) Motherboard/Control/Power Card :It is the Heart of Inverter having DSP ,Power Supply Section.

(2) DC-DC Card:- This card is used to provide DC voltage of various ranges like +15V and +5V with isolated ground to mother board card. (3) Driver Card :- This card is used to drive IGBTs . Contains HBridge . (4) Charger Card(Online):- In online UPS we use different charging card and its parameters are set manually . In online UPS charging are done through SCR and discharging through IGBTs. (5) OPTO CARD:- This card is used in 3P inverter and UPS to make DC pure for DSP . (6) SCR CARD:-This card is used in OFF line UPS static and its role is to provide Changeover to and from battery to Mains. .

(7)I/P and O/P Xmer Card:- On this card we have mounted PCB mounted transformer to sense Input and output AC voltages (8) CTs :- CTs are used to sense O/P Current. (9) Shunt :- These are used to check battery charging current and also used to sense over load condition.

Lower VA Systems:Sine Wave:Inverters/HUPS :-600 VA/12V,800 VA/12V,1400VA/24V HUPS DLX :-600,800,1400 VA HUPS Proton :-675,875,1500,1KVA,2KVA Static UPS :-2.5KVA,3.5KVA Inverters :-2.5KVA/48V,3.5KVA/48V Square Wave/Super Backup:400,600,800 VA Solar UPS:- 600,800,1500 VA 2.5 KVA,3.5 KVA

Overview of Product of Higher KVA

Inverter (1P-1P)
5KVA/96V 5KVA/120V 7.5KVA/120V 7.5KVA/180V 7.5KVA/240V 10KVA/180V 10KVA/192V 10KVA/240V

ON LINE UPS(1P-1P)
1KVA/180V 1KVA/168V 2KVA/180V 3KVA/168V 3KVA/180V 5KVA/180V 7.5KVA/192V 10KVA/192V

Inverter (3P-3P)
6KVA/180V 8KVA/180V 10KVA/240V 10KVA/360V 15KVA/240V 20KVA/360V 30KVA/360V 40KVA/360V

ONLINE UPS (3P-3P)

5KVA/360V 6KVA/360V 7.5KVA/360V 10KVA/360V 15KVA/360V 20KVA/360V 30KVA/360V 60KVA/360V

ON LINE UPS (3P-1P)

7.5KVA/360V 15KVA/360V

Static UPS(1P-1P)
5KVA/96V

Low battery:- if the battery voltage falls below specified limit

e.g.10.5 volt/battery the system will produce audio and video(LED/LCD) alarm . At the same time system will restart 4 times to check battery status and if the battery is still below set limit ,then inverter will go into permanent shutdown mode. And save battery from deep discharging. Overload/Short Ckt:-In the backup mode if the load is greater then 100% but less then 110%,then system will generate audio and video alarm . But if the load increases to 120% of its limit, then DSP will automatically shutdown the output power and retry 6 times . But if the condition is same then it will shutdown power permanently to protect system. The load greater the 300% is considered as short circuit condition.

Mains Fuse Blown:-If AC line is available and load increases

from MCB rating ,then inverter will show indication of Mains Fuse blown.
Reverse Phase/Wiring Protection.:-If the AC Line is back Feed

in the output socket ,then DSP will stop inverter working and show indication on the panel.
High Cut and Low Cut:-Here we are talking about high and

low mains so that system can move system into backup mode under these type of condition .In UPS mode the low value is 180 volt and its recovery voltage level is 190 V but in inverter mode LC is 100V and LCR is 110V.Simillarly in HC in UPS is 265 V and HCR is 255V but in Inverter mode HC is 280 V and HCR is 270V.

Change over time:- There are two type of Change over, one is Mains to Back-Up and another is Back-Up to mains . Mains to Back-Up: UPS mode: In this mode Time is very much critical in case of Mains to back-up instead of synchronization and slow start . Inverter mode : In this mode Time is not very much critical as it is in UPS mode so slow start is provided. Back-Up to mains When the systems switches from back-up to mains ,it is very much important to consider synchronization of pulse instead of time both in UPS mode and inverter mode.

There few important things that are required to understand changing and discharging profile of battery.
Boost Voltage : The voltage level of battery after which ,its

charging voltage stop increasing and after this level the charging current start decreasing to floating current. Usually this voltage is 14.5V

Float Voltage : The voltage of battery at which the its charging

current equals to floating current . Usually this voltage is 13.5V

Discharging Current:-

Various visual and audio indications are used to indicate low battery .Once the inverter is on ,The battery voltage start decreasing from 12.70 volt to 10.46 volt linearly and accordingly battery current changer from 38.6A to 40.1 A.At the same time The output AC voltage at full battery is 211V AC ,49.9Hz and decreasing to 185V AC. One battery voltage reaches to less then 10.4v,the inverter will take 4 time restart to check battery status again ,but if the condition is same ,then DSP will permanently shutdown the output AC voltage.

Charging Profile:14.5v(Boost Stage) 13.5v(Float Stage)

V
Controlled by DSP

II

III
~1A(Float Current)

T
There are three stages used to define charging profile of battery Stage I:- During this stage battery voltage keep on charging till its voltage not reaches to 14.5V i.e Boost stage with constant current of ~10.5 A. Stage II: Under this stage then battery voltage will remains 14.5V till its current not start decreasing to floating current ~1A. And this current is controlled by controlling the gate of IGBT/MOSFET.

Stage III: Once the currents reaches to floating current then battery voltages automatically decreases to floating voltage. High Charging /Normal Charging:- There are two type of charging modes for battery charging .The high charging is uses to speed up the process of charging where usually AC line cuts frequently. The difference between HC and NC is near about 2-3 A .and this is achieved by controlling the gates of IGBT/MOSFETS.

Total Battery Back-Up Time:Total Power = { (Inverter/HUPS VA)*Power Factor} Backup Time = {(Total Battery Voltage)*(Ah)}/(HUPS VA) Example :So, = (48 x 150)/(3500) =2.05 Hr. backup we will get. Say we have 3.5 KVA Static UPS Connected with 48 V Batt. and Battery Ah is 150

Efficiency Calculations:-

= [{(AC Vout x Iout x PF)}x 100]/{DC Vin x Iin}

Example :- = ((199 x 3.9 x 1)x 100)/(22.79x43.1) = 79%

Solar Inverter:-It converts the variable direct current (DC) output of a photovoltaic (PV) solar panel into a utility frequency alternating current (AC) that can be fed into a commercial electrical grid or used by a local, off-grid electrical network. These are special inverters which are designed to draw energy from a battery, manage the battery charge via an onboard charger, and export excess energy to the utility grid. These inverters are capable of supplying AC energy to selected loads during a utility outage, and are required to have anti-islanding protection.

Solar Panel

Mains Supply

Power Stage

Power X-mer

Relay/SCR

Load

Battery Bank

DSP CONTROL

Input Parameters (Analog ) Main Sense ,Temp , Battery VTG , o/p VTG, o/p freq, Battery Charging & Discharging I (Digital) On/Off Switch, HC/NC,UPS/INV., PWM Start/Stop

Processing Unit

Output Parameters (Digital LED/LCD) Inverter ON , Low Batt ., Over load , Batt Charging , Mains ON/OFF, Short CKT. O/P Freq, Load %,Efficiency

PWM FOR SIN WAVE

Buzzer ,FAN ,Main Change over Switch

As we know firmware is the heart of any electronic machine/equipment . In the last slide we have seen the role of firmware of HUPS according to input and outputs. We are using Freescale DSP and Controllers Sine wave:For lower VA systems up to 3.5KVA(Static) -------- 56F8013 2.5 KV to Higher HUPS/Inverts Single Phase-------56f801 Single phase Online UPS ---------------------------56f801 Three phase Inverter and Online UPS---------------56f807 Square wave:400 and 800 VA is in PIC16f872 600 VA and MPPT is in MC9s08QE8

Tuning tool is used to calibrate HUPS/Inverter/Online UPS With the Help of this software we can be able to analyze system performance and also its data can be logged for further processing .

Parameters :(1) Main Voltage (Read/Write) (2) Main Frequency(Read Only) (3) Charging Current (Read/Write) (4) Temperature (Read only) (5) Battery Voltage (Read/Write) (6) Battery Voltage Dis (Read only) (7) Output Voltage (Read/Write) (8) Output Current (Read only) (9) Discharging Current (Read/Write) (10) Ref Signal (Read only) Buttons:- Erase :- This is used to erase data from the memory. Exit :- To Close program Tune Variable :- This button becomes active iff you will change any of the read /write parameter.

PCB Design:- We are using Protel99SE Software for designing PCB schematic and layout , for generation of Gerber data. Three files are important to understand (1) .SCH File:- This file contains electrical circuit of the PCB. With the help of this we can create the create net list which will be further used to import circuit in layout creation. (2) .PCB File:- We create .PCB file on which we import net list and make the layout. (3) Gerber file : After the creation of Layout ,we will use Gerber tool to create Gerber file that will be used by PCB manufacturer . As our product is related to power generation so we are using FR-4 material (Fire epoxy).Double side with 70micron copper pouring on both side.

Electrical Inputs

Circuit Design (.SCH)

Create Net list

Not OK Check
Create LAYOUT (.PCB)

Check with Requirement

OK
Gerber File Send for production

CAD Design:- This is used to design mechanical part of any product that includes both unique and customized items . We used Pro-E for 3-D creation of any mechanical part and Auto-CAD for drawings. Make the drawings According to Inputs And 3D Const.

Mechanical Inputs

Final Verification

check Not OK
Production

Sample ok If sample ok then production

Send to vendor for sample

Requirement Generation

Approval From HOD

Locate Area

Purchase Request (Self/Purchase Deptt.)

Code and vendor Creation in SAP

Quotation Generation

P.O TO Supplier

Delivery

It stands for System Application and Products in data Processing .It was developed by SAP AG German MNC in 1972 and is now globally accepted by keeping in the mind to make one s/w through which management can able to check /Analyze various departments from any where. This also helps to maintain different documents related to each department and also to overcome from the burden of hard data logging. We are in GENUS using SAP ver6. SAP is designed in such a way that every item ,document , PCB etc. are having unique codes so that user can interact with system on the basis of that unique codes.

Major Modules followed are: FICO :-Finance and Control MM

:-Material Management SD :-Sales and Distribution QM :-Quality Management HCP :-Human Capital Planning PP :-Production Planning WM :-Warehouse Management
These modules are further having different transaction and

each transaction have unique codes .

SAP Log On screen

Log On button

Server Name

SAP Log On screen

SAP screen

SAP Menu

Creating A New Material

Displaying Bill Of Material (BOM)

Documentation of any project means the way how best current team

(working on project) can explain the things /project so that it can be easy to use by another new/old person may be associated with that or not. Documentation is needed for standardization of work and this gives complete information about work which can be used when needed. Terms Used For Documentation:NPDL - New Project Development & Launch Toll Gate Gateway of Project development cycle BOM Bill of Material Change Note The document in which any change is

shown. Deviation Note Any deviation from previous quantity is shown in this document

NDPL

Business and Market Survey

Kick Off Meeting

Approval and Core Team Selection

Design Planning

Mechanical and Electrical Design inputs

H/W Implementation

S/W implementation

Prototype Development

Prototype validation

Prototype Release

Mass Production

Thank you Very Much